Researchers at the Institute of Nanoscience and Materials of Aragon and the IMDEA Materials Institute in Spain have developed a new material that could significantly impact the electric vehicle (EV) industry. Published in Science, the research focuses on a chemical doping process that improved carbon nanotube conductivity 17-fold while maintaining structural integrity. The treated fibers reach about 40% of copper's electrical output at ambient temperature and exceed aluminum's conductivity on a weight-adjusted basis. Weighing roughly one-sixth of copper while offering five times the tensile strength, the material addresses a long-standing challenge in nanotube development: achieving high current-carrying capacity without compromising durability.
The key innovation involves treating the fibers with tetrachloroaluminate (AlCl4-), a dopant that introduces charge carriers without disrupting the atomic lattice. Preserving structural integrity is critical for practical applications. Modern EVs carry significant copper loads, especially in high-voltage wiring bundles, and replacing copper with a lighter material reduces vehicle mass, extends range, and lowers heat buildup. For drones, reduced cable mass translates directly into longer flight times, and for aircraft developers, weight reduction yields outsized returns.
The material also demonstrates reliable performance in dry conditions and acceptable moisture tolerance, meeting transportation certification standards. On specific conductivity—the benchmark manufacturers prioritize most—the treated fibers have entered territory that warrants serious engineering attention. At peak values, they exceed aluminum's conductivity on an absolute basis.
Remaining challenges include manufacturing consistent fibers at scale, ensuring hardware compatibility, and establishing a cost profile competitive with conventional metals. If these issues are resolved, the technology could move from laboratories into the electrical systems of next-generation EVs and aircraft. Recycling infrastructure for these materials will also need development. Many automotive firms, such as Ferrari N.V. (NYSE: RACE), are monitoring whether this material becomes commercially available at scale and price points that make the switch from copper economically viable.
